Patent application title: Apparatus for shaping the end of an optical fiber

Abstract:

An apparatus is provided for shaping an end of an optical fiber. The
apparatus may include a frame and a clamp constructed to hold the optical
fiber in a fixed location relative to the frame. The apparatus may
further include a tip shaper supported by the frame and movable in a
first direction toward and away from the clamp, and moveable in a second
direction that lies in a plane transverse to the first direction to shape
the end of the optical fiber when the tip shaper is placed in contact
with the optical fiber. The apparatus may include an abrasive substrate
which abrades the end of the fiber.

Claims:

1. An apparatus for shaping an end of an optical fiber, the apparatus
comprising:a frame;a clamp constructed and arranged to hold the optical
fiber in a fixed location relative to the frame; anda tip shaper
supported by the frame, the tip shaper being movable in a first direction
toward and away from the clamp, and moveable in a second direction that
lies in a plane transverse to the first direction to shape the end of the
optical fiber when the tip shaper is placed in contact with the optical
fiber.

2. The apparatus of claim 1, wherein the tip shaper comprises an abrasive
substrate to shape the end of the optical fiber and at least one
substrate support that is supported by the frame, the abrasive substrate
being advanceable along at least a portion of the substrate support.

3. The apparatus of claim 2, wherein the at least one substrate support
includes a plurality of substrate supports constructed and arranged to
provide different optical fiber shaping characteristics.

4. The apparatus of claim 1, wherein the clamp is supported by the frame.

5. The apparatus of claim 4, wherein the clamp is detachably coupled to
the frame.

6. The apparatus of claim 1, wherein the tip shaper comprises an abrasive
substrate to shape the end of the optical fiber, the abrasive substrate
having at least a first region and a second region adjacent the first
region, the first region having first abrasive properties and the second
region having second abrasive properties that are different from the
first abrasive properties to provide different shaping characteristics
along the abrasive substrate.

7. The apparatus of claim 2, wherein the tip shaper further comprises a
first reel and a second reel, wherein at least a portion of the abrasive
substrate is unwound from the first reel as the abrasive substrate is
advanced along a portion of the substrate support, and wherein at least a
portion of the abrasive substrate is wound onto the second reel as the
abrasive substrate is advanced along a portion of the substrate support.

8. The apparatus of claim 7, wherein the tip shaper further comprises a
cartridge which supports the abrasive substrate, the first reel and the
second reel, and wherein the cartridge is detachably coupled to the
frame.

9. The apparatus of claim 1, wherein movement in the second direction
includes orbital movement.

10. An apparatus for shaping an end of an optical fiber, the apparatus
comprising:a frame;a tip shaper supported by the frame and moveable
relative to the frame to shape the end of the optical fiber when the tip
shaper is placed in contact with the optical fiber; anda counterweight
supported by the frame, the counterweight being constructed and arranged
to maintain a predetermined force between the tip shaper and the end of
the optical fiber when the tip shaper is shaping the end of the optical
fiber independent of the orientation of the tip shaper.

11. The apparatus of claim 10, wherein the counterweight is moveable in a
linear direction relative to the frame.

12. The apparatus of claim 10, further comprising a clamp constructed and
arranged to hold the optical fiber in a fixed location relative to the
frame.

13. The apparatus of claim 12, wherein the tip shaper is movable in a
first direction toward and away from the clamp.

14. The apparatus of claim 13, wherein the tip shaper is moveable in a
second direction that lies in a plane transverse to the first direction
to shape the end of the optical fiber when the tip shaper is placed in
contact with the optical fiber.

15. The apparatus of claim 10, further comprising a pulley system coupling
the counterweight to the tip shaper.

16. An apparatus for shaping an end of an optical fiber, the apparatus
comprising:a frame;a clamp constructed and arranged to hold the optical
fiber in a fixed location relative to the frame;a tip shaper supported by
the frame and moveable relative to the frame to shape the end of the
optical fiber when the tip shaper is placed in contact with the optical
fiber; anda fiber support constructed and arranged to support an end
portion of the optical fiber, the fiber support being movable along the
end portion of the optical fiber in response to the tip shaper shaping
the end of the optical fiber.

17. The apparatus of claim 16, wherein the fiber support has an axial
passage adapted to receive the optical fiber therethrough, the fiber
support being movable in an axial direction relative to the end portion
of the optical fiber.

18. The apparatus of claim 16, wherein the tip shaper is movable in a
first direction toward and away from the clamp and in a second direction
that lies in a plane transverse to the first direction to shape the end
of the optical fiber when the tip shaper is placed in contact with the
optical fiber.

19. The apparatus of claim 16, wherein the fiber support is biased in a
direction toward the tip shaper.

20. The apparatus of claim 16, wherein the tip shaper comprises an
abrasive substrate to shape the end of the optical fiber and a substrate
support that is supported by the frame, the abrasive substrate being
advanceable along at least a portion of the substrate support.

21. The apparatus of claim 16, wherein the tip shaper comprises an
abrasive substrate to shape the end of the optical fiber, the abrasive
substrate having at least a first region and a second region adjacent the
first region, the first region having first abrasive properties and the
second region having second abrasive properties that are different from
the first abrasive properties to provide different shaping
characteristics along the abrasive substrate.

22. An apparatus for shaping an end of an optical fiber, the apparatus
comprising:a frame;a clamp constructed and arranged to hold an optical
fiber in a fixed location relative to the frame; anda tip shaper
supported by the frame and moveable relative to the frame to shape an end
of the optical fiber when the tip shaper is placed in contact with the
optical fiber, the tip shaper including an abrasive substrate having at
least a first region and a second region adjacent the first region, the
first region having first abrasive properties and the second region
having second abrasive properties that are different from the first
abrasive properties to provide different shaping characteristics along
the abrasive substrate.

23. The apparatus of claim 22, wherein the abrasive substrate has a third
region adjacent the second region, the third region having third abrasive
properties that are different from the first and second abrasive
properties to provide different shaping characteristics along the
abrasive substrate.

24. The apparatus of claim 23, wherein the abrasive substrate includes a
first layer and a second layer disposed over the first layer, the second
layer having a first opening extending therethrough to expose a portion
of the first layer, the portion of the first layer forming the first
region, at least a portion of the second layer forming the second region
adjacent the first region; andwherein the abrasive substrate further
includes a third layer disposed over of the second layer, the third layer
having a second opening extending therethrough to expose a portion of the
second layer, the portion of the second layer forming the second region,
at least a portion of the third layer forming the third region adjacent
the second region.

25. The apparatus of claim 22, wherein the abrasive substrate includes a
first layer and a second layer disposed over the first layer, the second
layer having a first opening extending therethrough to expose a portion
of the first layer, the portion of the first layer forming the first
region, at least a portion of the second layer forming the second region
adjacent the first region.

Description:

FIELD OF THE INVENTION

[0001]The present invention relates to optical fibers, and more
particularly, to an apparatus for shaping an end of an optical fiber.

BACKGROUND OF INVENTION

[0002]Fiber optic systems are used in a variety of applications. In a
fiber optic system, information in the form of a light signal is
transmitted between different portions of the fiber optic system through
an optical fiber. End faces of two optical fibers may be axially aligned
and placed into contact under a predetermined axial load to make a
point-to-point signal connection.

[0003]To transmit the light signal through the fiber optic system, it is
important for an end face of an optical fiber to have desired surface
characteristics so that the end face may interface suitably with other
components in the fiber optic system. An optical fiber end face that does
not have desired surface characteristics may result in signal loss and
degraded optical performance of the fiber optic system. In some
circumstances, an optical fiber with an end surface that does not have
desired surface characteristics may render the optical fiber inoperable.

[0004]It may be desirable for the end face of an optical fiber to be
smooth and/or flat. In some circumstances, it may be desirable for the
end face of the optical fiber to be square, such that the end face is
substantially perpendicular to the axis of the fiber. In other
circumstances, it may be desirable for the end face of an optical fiber
to have a curved shape.

[0005]Cleaving and polishing an optical fiber are two conventional
approaches to obtaining the desired surface characteristics of an optical
fiber end face. Traditionally, cleaving and polishing are performed in a
controlled manufacturing environment.

[0006]In a less controlled environment, such as in a field environment, it
may still be desirable to process an end face to achieve desired surface
qualities. For example, for various types of optical fiber repair and
maintenance work, such as splicing fibers and repairing connectors, it
may be desirable to process the fiber to achieve a smooth, flat, curved,
and/or square end surface as part of the repair or maintenance work.
However, it may be difficult to achieve these desired optical fiber end
surface characteristics in an uncontrolled environment using known
cleaving and polishing devices.

[0007]It is thus an object of the present invention to provide an
apparatus for shaping an end of an optical fiber to provide desired
surface characteristics.

SUMMARY OF INVENTION

[0008]In one illustrative embodiment of the present invention, an
apparatus is provided for shaping an end of an optical fiber. The
apparatus includes a frame and a clamp constructed and arranged to hold
the optical fiber in a fixed location relative to the frame. The
apparatus also includes a tip shaper supported by the frame. The tip
shaper is movable in a first direction toward and away from the clamp and
is moveable in a second direction that lies in a plane transverse to the
first direction to shape the end of the optical fiber when the tip shaper
is placed in contact with the optical fiber.

[0009]In another illustrative embodiment, an apparatus is provided for
shaping an end of an optical fiber. The apparatus includes a frame and a
tip shaper supported by the frame and moveable relative to the frame to
shape the end of the optical fiber when the tip shaper is placed in
contact with the optical fiber. The apparatus further includes a
counterweight supported by the frame. The counterweight is constructed
and arranged to maintain a predetermined force between the tip shaper and
the end of the optical fiber when the tip shaper is shaping the end of
the optical fiber independent of the orientation of the tip shaper.

[0010]In a further illustrative embodiment, an apparatus is provided for
shaping an end of an optical fiber. The apparatus includes a frame, a
clamp constructed and arranged to hold the optical fiber in a fixed
location relative to the frame, and a tip shaper supported by the frame
and moveable relative to the frame to shape the end of the optical fiber
when the tip shaper is placed in contact with the optical fiber. The
apparatus also includes a fiber support constructed and arranged to
support an end portion of the optical fiber. The fiber support is movable
along the end portion of the optical fiber in response to the tip shaper
shaping the end of the optical fiber.

[0011]In yet another illustrative embodiment, an apparatus is provided for
shaping an end of an optical fiber. The apparatus includes a frame, a
clamp constructed and arranged to hold an optical fiber in a fixed
location relative to the frame, and a tip shaper supported by the frame
and moveable relative to the frame to shape an end of the optical fiber
when the tip shaper is placed in contact with the optical fiber. The tip
shaper includes an abrasive substrate having at least a first region and
a second region adjacent the first region, the first region having first
abrasive properties and the second region having second abrasive
properties that are different from the first abrasive properties to
provide different shaping characteristics along the abrasive substrate.

[0012]Various embodiments of the present invention provide certain
advantages. Not all embodiments of the invention share the same
advantages and those that do may not share them under all circumstances.

[0013]Further features and advantages of the present invention, as well as
the structure of various embodiments of the present invention are
described in detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0014]In the drawings, each identical or nearly identical component that
is illustrated in various figures is represented by a like numeral. For
purposes of clarity, not every component may be labeled in every drawing.

[0015]Various embodiments of the invention will now be described, by way
of example, with reference to the accompanying drawings, in which:

[0016]FIG. 1 is a schematic view of an apparatus for shaping an optical
fiber according to one illustrative embodiment;

[0017]FIG. 2 is a front perspective view of an apparatus for shaping an
optical fiber according to one illustrative embodiment;

[0018]FIG. 3 is a back perspective view of the apparatus shown in FIG. 2;

[0019]FIG. 4 is a front perspective view of the linear carriage and the
orbital carriage included in the apparatus shown in FIG. 2;

[0020]FIG. 5 is a back perspective view of the linear carriage and the
orbital carriage shown in FIG. 4;

[0021]FIG. 6 is a back perspective view of the orbital carriage included
in the apparatus shown in FIGS. 2-5;

[0022]FIG. 7 is a front perspective view of the orbital carriage shown in
FIG. 6;

[0023]FIG. 8 is a front perspective view of the linear carriage and
counterweight included in the apparatus shown in FIGS. 2-5;

[0024]FIG. 9 is a perspective view of a cartridge for supporting an
abrasive substrate included in the apparatus shown in FIG. 2;

[0025]FIGS. 10A-10D are schematic views of an abrasive substrate according
to one illustrative embodiment;

[0026]FIG. 11 is front perspective view of the fiber support assembly
according to one illustrative embodiment included in the apparatus shown
in FIG. 2;

[0027]FIG. 12 is an exploded view of the fiber support assembly shown in
FIG. 11;

[0028]FIG. 13 is a cross-sectional view of a portion of the apparatus
shown in FIG. 2 illustrating the fiber support assembly shown in FIGS. 11
and 12;

[0029]FIG. 14 is a perspective view of an apparatus for shaping an optical
fiber including a housing according to one illustrative embodiment; and

[0030]FIG. 15 is a block diagram for a main processor according to one
illustrative embodiment.

DETAILED DESCRIPTION

[0031]The present invention is directed to an apparatus for shaping the
end face of an optical fiber. It should be appreciated that the apparatus
may be configured in any of numerous ways, and that the present invention
is not limited to the particular apparatus and techniques described
below.

[0032]Aspects of the invention are directed to an apparatus which may
shape the fiber to achieve desired end surface characteristics. As
mentioned above, an optical fiber end face that does not have desired
surface characteristics may result in signal loss and degraded optical
performance of a fiber optic system. Certain embodiments are directed to
an apparatus for shaping an optical fiber to obtain an end surface having
one or more desired surface characteristics, including, but not limited
to a flat, smooth, curved and/or square end face.

[0033]According to one aspect of the present invention, the end of an
optical fiber to be shaped by the apparatus may be substantially bare
(i.e., where various components, such as a ferrule or terminus have been
removed, and/or coatings have been removed or stripped from the fiber).
It is also contemplated that another aspect of the present invention is
directed to an apparatus for shaping the end of an optical fiber which
includes one or more coatings and/or components, such that shaping the
end of the optical fiber may also shape portions of the coatings and/or
components.

[0034]As set forth in more detail below, aspects of the present invention
are directed to an apparatus which may be particularly suitable for
shaping an end of an optical fiber positioned in a field environment
(i.e. outside a controlled manufacturing environment), such as, but not
limited to a military or industrial environment. In one embodiments, an
apparatus is particularly suitable for optical fiber repair and
maintenance work, such as, but not limited, to splicing optical fibers
and repairing optical fiber connectors.

[0035]The apparatus of the present invention may include a tip shaper
configured to shape an end of an optical fiber. The apparatus may be
configured to place the tip shaper in contact with the fiber. The
apparatus may include a frame which supports the tip shaper and a clamp
to hold the optical fiber in a fixed location or position relative to the
frame.

[0036]In one embodiment, the tip shaper may be movable in a first
direction toward and away from the clamp. The tip shaper may also be
movable in a second direction that lies in a plane transverse to the
first direction to shape the end of the optical fiber when the tip shaper
is in contact with the optical fiber. The optical fiber may remain in a
fixed position and the tip shaper may both move toward the optical fiber
until it contacts the fiber and the tip shaper may also move relative to
the optical fiber to shape the end of the optical fiber. In one
embodiment, the first direction may include linear movement. In one
embodiment, the second direction may include linear movement, orbital
movement, or a combination of linear and orbital movement. It is to be
understood that the tip shaper may be configured to employ other movement
suitable for shaping the fiber.

[0037]The tip shaper may include an abrasive substrate that shapes the
optical fiber by abrading the end of the optical fiber. It should be
recognized that in one embodiment, the shaping of the end of the optical
fiber may be analogous to a sanding or polishing action and the abrasive
substrate may include a sandpaper-like material. The tip shaper may also
include a substrate support that supports the substrate and along which
the abrasive substrate may be advanceable. The shape and rigidity of the
substrate support may be selected based upon the desired optical fiber
end face surface characteristics.

[0038]There are various factors associated with shaping an optical fiber.
Factors such as the amount of force between the optical fiber and the tip
shaper, the amount of time the optical fiber contacts the tip shaper, and
the abrasive properties of the abrasive substrate may be adjusted to vary
the amount the end of the optical fiber is shaped. In general, the
greater the force between the optical fiber and the tip shaper, the
greater the amount of shaping or abrading of the fiber. Similarly, the
greater the time the optical fiber contacts the tip shaper, the greater
the amount of shaping or abrading of the fiber. Furthermore, the more
abrasive the abrasive substrate the greater the amount of shaping or
abrading of the fiber. The apparatus may be configured to control one or
more factors for shaping the fiber.

[0039]Illustrative embodiments of the apparatus for shaping an optical
fiber may include a counterweight arrangement to maintain a predetermined
force between the tip shaper and the end of the optical fiber when the
tip shaper is shaping the end of the optical fiber independent of the
orientation of the tip shaper or fiber. An operator may vary the
orientation of the apparatus to contact and shape the end of the optical
fiber. The apparatus may, for example, contact and shape an optical fiber
having an upward facing end face, a downward facing end face, or any
other potential orientation. The counterweight may operate to ensure that
a predetermined force is applied by the tip shaper against the optical
fiber regardless of the relative orientation between the tip shaper and
the fiber and/or the gravitational effects on the apparatus.

[0040]Other illustrative embodiments of the present invention are directed
to an apparatus for shaping an optical fiber which includes a fiber
support to support an end portion of the optical fiber. The fiber support
may be movable along the end portion of the optical fiber in response to
the tip shaper advancing against the end of the optical fiber during the
shaping process. In one embodiment, the optical fiber may be held by the
clamp in a cantilevered relationship and the fiber support may be
configured to provide support to the cantilevered end of the fiber.

[0041]Another aspect of the present invention is directed to an apparatus
for shaping an optical fiber having a tip shaper that includes an
abrasive substrate having regions with different abrasive properties. In
one embodiment, the abrasive substrate may include at least a first
region and a second region adjacent the first region, where the first
region may have first abrasive properties and the second region may have
second abrasive properties that are different from the first abrasive
properties to provide different shaping characteristics along the
abrasive substrate. The abrasive properties of the abrasive substrate may
vary along the length of the abrasive substrate. As discussed in greater
detail below, aspects of the present invention are directed to a
multi-layered abrasive substrate having different shaping
characteristics.

[0042]Further aspects of the invention are directed to an automated
apparatus for shaping an optical fiber. An automated apparatus may
enhance the effectiveness of the apparatus to shape an optical fiber and
may help to minimize optical fiber damage which may result from operator
error. The apparatus may include one or more automated features
including, but not limited to, controlling the advancement of the
abrasive substrate, controlling the movement of the tip shaper,
controlling the force the tip shaper exerts against an end of an optical
fiber, controlling the length of time to shape an optical fiber, and
controlling the dispensing of a fluid onto the abrasive substrate. It is
contemplated that in one embodiment, an automated apparatus is provided,
such that once the operator actuates a trigger, no further input may be
required to achieve an end face having desirable surface characteristics.
However, it should be appreciated that other embodiments of the present
invention may employ one or more features that are not automated.

[0043]Aspects of the invention are also directed to a hand-held apparatus
for shaping an optical fiber. As the use of fiber optic systems continues
to increase, there is an increasing need for a field service tool which
can quickly and effectively shape an end of an optical fiber during
repair and maintenance work. For example, in one embodiment, a hand-held
apparatus is provided for shaping an optical fiber such that splicing and
connector repair work may be performed in a field environment. It should
be appreciated that each embodiment of the present invention is not
limited to a hand-held device.

[0044]Turning now to the drawings, it should be appreciated that the
drawings illustrate various components and features which may be
incorporated into one or more embodiments of the present invention. For
simplification, several drawings may illustrate more than one optional
feature or component. However, the present invention is not limited to
the specific embodiments disclosed in the drawings. It should be
recognized that the present invention encompasses one or more embodiments
which may include only a portion of the components illustrated in any one
figure, and/or may also encompass one or more embodiments combining
components illustrated in multiple different drawings, and/or may also
encompass one or more embodiments not explicitly disclosed in the
drawings.

[0045]FIG. 1 illustrates a schematic view of one embodiment of an
apparatus 100 for shaping an optical fiber 50. In this illustrative
embodiment, the apparatus 100 includes a frame 20 and a clamp 40 arranged
to hold an optical fiber 50 in a fixed location relative to the frame 20.
A tip shaper 60 is supported by the frame 20 and is movable relative to
the clamp 40 and the optical fiber 50 to shape the end 52 of the fiber
50.

[0046]In one embodiment, the tip shaper 60 is moveable in a first
direction which may be linear with movement toward the clamp 40 being
substantially in the direction of arrow A and movement away from the
clamp 40 being substantially in the direction of arrow A'. It should be
appreciated that in other embodiments, the movement of the tip shaper in
the first direction may be non-linear.

[0047]In one illustrative embodiment, the tip shaper 60 is also moveable
in a second direction that lies in a plane transverse to the first
direction A-A' to shape the end 52 of the optical fiber 50 when the tip
shaper 60 is placed in contact with the optical fiber 50. In one
embodiment, movement of the tip shaper 60 in the second direction may
include orbital movement in the B-B' plane. It is also contemplated that
movement of the tip shaper 60 in the second direction may include linear
movement, and may, for example include movement of the tip shaper 60 in
the direction of arrow B, in the direction of arrow B', back and forth
movement in the direction of both arrow B and B', or a combination of
linear and orbital movement as the invention is not so limited.

[0048]As shown, in one embodiment, the movement of the tip shaper 60 in
the second direction is perpendicular to the first direction of movement
A-A'. It should be appreciated that in other embodiments, the movement of
the tip shaper 60 in the second direction may lie in a plane transverse
to the first direction but not perpendicular to the first direction of
movement.

[0049]The movement of the tip shaper 60 in the second direction shapes the
end surface of the optical fiber 50 when the tip shaper 60 is placed into
engagement with the optical fiber 50. In this regard, the tip shaper 60
may abrade, grind, sand, or polish the end surface. In one embodiment,
repeated contact between the abrasive substrate 70 and the end 52 of the
fiber 50 may shape the end of the fiber by abrading the end face to
achieve desirable surface characteristics. In one embodiment, it may be
desirable for the end face to be smooth and flat to optimize optical
performance. In another embodiment, it may be desirable for the optical
fiber to have a curved end face to optimize optical performance.

[0050]In embodiments where the tip shaper 60 is configured to move
orbitally in the second direction, the tip shaper 60 may include an
orbital carriage 80 coupled to the frame 20. One embodiment of an orbital
carriage 80 is shown in greater detail in FIGS. 2 and 4-7. In this
particular embodiment, the orbital movement of the tip shaper 60 is in a
plane transverse to the axis 162 of the optical fiber.

[0051]In one illustrative embodiment, an actuator 82 such as an orbit
motor, rotates a motor pulley 86 to initiate the orbital movement of the
carriage 80. A drive belt 84 may extend around the motor pulley 86
coupling the motor pulley 86 to a pair of orbit drive pulleys 88 (see
FIGS. 2, 4 and 5) to rotate the drive pulleys 88. In one embodiment, the
orbital carriage 80 rotates due to the center of rotation of the orbit
drive pulley assembly 80 being offset from the center of rotation of the
orbital shafts 122. It should be appreciated that the above-described
crankshaft-type mechanism is one approach to imparting orbital movement
to the tip shaper 60. Other types of mechanisms and actuators apparent to
one of skill in the art may be used to orbitally move the tip shaper 60
relative to the frame 20 and/or the clamp 40, as the invention is not so
limited.

[0052]In one embodiment, the orbital carriage 80 may include one or more
counterbalance weights 120 to reduce vibrations throughout the apparatus
100 that may be generated by the orbital movement of the orbital carriage
80. In the embodiment illustrated in FIGS. 2-5, the orbital carriage 80
includes four counterbalance weights 120 with two counterbalance weights
120 spaced apart on each end of the shafts 122. The total moment of
inertia of the counterbalance weights 120 may be approximately equal to
the total moment of inertia of the orbital carriage 80 and the
components, such as the tip shaper 60, which orbit with the orbital
carriage 80. The counterbalance weights 120 may be configured to rotate
in the same direction as the orbital carriage 80, but 180 degrees out of
phase, to counteract and balance out the moving weight of the orbital
carriage 80.

[0053]In this illustrative embodiment, each counterbalance weight 120 is
configured with a substantially half cylindrical shape. It should be
recognized that the counterbalance weights 120 may be configured with
other suitable shapes apparent to one of skill in the art. Furthermore,
it should be recognized that not all embodiments of the present invention
include counterbalance weights, as the invention is not so limited.

[0054]It should be appreciated that the orbital carriage 80 may be
configured to continuously rotate the tip shaper 60 in one direction. It
is contemplated that the orbital carriage 80 may be configured to rotate
the tip shaper 60 in multiple directions. For example, the orbital
carriage 80 may rotate in one direction, such as clockwise, and
thereafter rotate in another direction, such as counterclockwise.

[0055]It is also contemplated that other types of mechanisms and actuators
(not shown) apparent to one of skill in the art may be used to generate
rotational movement of the tip shaper 60. Furthermore, it should be
appreciated that rotational and/or linear movement of the tip shaper 60
is not required for each embodiment of the shaping apparatus.

[0056]In one illustrative embodiment, the optical fiber is held by clamp
40 such that the end 52 of the optical fiber 50 remains in a fixed
location as the tip shaper 60 moves to shape the optical fiber 50. In one
illustrative embodiment shown in FIG. 2, the clamp 40 includes a clamp
lever 42 to secure the fiber in the clamp 40. The clamp 40 may hold the
optical fiber 50 at one or more locations 54 inwardly spaced from the end
52 of the optical fiber.

[0057]In one illustrative embodiment, the clamp 40 is supported by the
frame 20. In one embodiment, the clamp 40 may be detachably coupled to
the frame 20 such that the clamp 40 and optical fiber 50 may be
selectively coupled to the frame 20. In another embodiment, the clamp 40
may be permanently attached to or be formed as part of the frame 20. It
should be appreciated that in another embodiment, the clamp 40 may be
separate from the frame 20. For example, in one embodiment, the clamp 40
may be supported by another frame (not shown).

[0058]As shown in the illustrative embodiment, the tip shaper 60 may
include an abrasive substrate 70 to shape the end 52 of the optical fiber
50. The abrasive substrate 70 may be configured to abrade the fiber 50
until an end surface with desired surface characteristics is achieved. In
this regard, the abrasive substrate 70 may be analogous to a
sandpaper-like material and may range from having a coarse surface to a
fine surface depending upon the particular application. The abrasive
characteristics of the abrasive substrate 70 are discussed more below,
but in general, a coarser abrasive substrate 70 may result in a rough
surface and may be used to abrade a greater amount of material from the
optical fiber 50. In contrast, a finer abrasive substrate 70 may result
in a fine surface and may be used to abrade a lesser amount of material
from the optical fiber 50.

[0059]The tip shaper 60 may include at least one substrate support 72
which may be supported by the frame 20 to act as a backing layer for the
abrasive substrate 70 as the abrasive substrate contacts and shapes the
fiber. The substrate support 72 may include a support surface which is
selected based upon the desired optical fiber end face surface
characteristics. In one embodiment, a substrate support 72 may include a
substantially rigid and flat support surface to create a flat optical
fiber end face. In one embodiment, the substantially rigid and flat
support surface may be formed from metal, such as stainless steel. In one
embodiment, the substrate support 72 may include a non-planar or curved
surface to create a non-planar or curved optical fiber end face. In one
embodiment, the support surface of the support substrate 72 may be formed
from a relatively flexible material, such as a rubber material like 60
durometer urethane, to shape the end face of the optical fiber to have a
slightly curved configuration. In one embodiment, the fiber may be shaped
to have a slightly convex end surface. As discussed below, the substrate
support 72 may be removeable based upon the desired end face surface
characteristics. In one embodiment, a plurality of substrate supports 72
may be provided to provide different optical fiber shaping
characteristics and an operator may select the substrate support 72 based
upon the desired optical fiber end face characteristics.

[0060]In one embodiment, the abrasive substrate 70 is advanceable along at
least a portion of the substrate support 72. The abrasive substrate 70
may be advanced along the substrate support 72, such as, for example, in
the direction of arrow B', to present a new or fresh portion of the
abrasive substrate 70 to the optical fiber. Once a first portion of the
abrasive substrate 70 contacts and shapes the optical fiber, the first
portion of the abrasive substrate 70 may be advanced away from the
optical fiber 50 in the direction of arrow B'.

[0061]In one embodiment, it may be desirable to advance a used portion of
abrasive substrate where the abrasive particles on the surface of the
substrate 70 begin to wear down. As discussed in greater detail below, in
other embodiments, it may be desirable to advance the first portion of
the abrasive substrate to present a new or fresh portion of the abrasive
substrate which may have different abrasive characteristics. It is also
contemplated that the advancement of the abrasive substrate 70 across the
fiber 50 may abrasively shape the end of the optical fiber. Advancement
of the abrasive substrate 70 along the substrate support 72 may be
continuous or intermittent.

[0062]In one illustrative embodiment, the abrasive substrate 70 may be
stored on a first reel 90 and a second reel 92. In one embodiment, a
supply of fresh or unused abrasive substrate 70 is provided on the first
reel 90 which acts as a feed reel. As the abrasive substrate 70 is
advanced from the first reel 90, the used portion of the abrasive
substrate 70 is stored on the second reel 92 which acts as a take-up
reel. In this regard, at least a portion of the abrasive substrate 70 may
be unwound from the feed reel 90 as the abrasive substrate 70 advances
along a portion of the substrate support 72. Once a portion of the
abrasive substrate 70 contacts and shapes the optical fiber, that used
portion of the abrasive substrate 70 may then be wound onto the take-up
reel 92.

[0063]A drive mechanism may be provided to advance the abrasive substrate
70 with respect to the substrate support 72. In one illustrative
embodiment, the drive mechanism rotates the second reel 92 in a counter
clockwise direction. The rotation of the second reel 92 may also draw
abrasive substrate 70 from the first reel 90 which may rotate the first
reel 90 in a counter clockwise direction. In one illustrative embodiment
shown in FIGS. 6-7, the drive mechanism may include an abrasive substrate
drive motor 130. The drive mechanism may also include a gear train 144 to
move the abrasive substrate 70 at an intermittent or constant rate. As
shown in FIG. 7, a pinch roller drive 142 may be provided to assist in
the winding of the abrasive substrate 70 onto the second reel 92. A pinch
roller engagement lever 148 may be provided to move the pinch roller
drive 142 into contact with the abrasive substrate 70 once the abrasive
substrate is positioned within the apparatus 100. It should be
appreciated that any suitable drive mechanism apparent to one of skill in
the art may be used to advance the abrasive substrate.

[0064]The tip shaper 60 may move in the first direction toward and away
from the clamp 40 in a variety of ways, as the invention is not so
limited. In one illustrative embodiment shown schematically in FIG. 1 and
in greater detail in FIGS. 2-5 and 8, a linear carriage 110 couples the
tip shaper 60 to the frame 20 to move the tip shaper 60 along the frame
20. A linear slide 114 may slideably couple the linear carriage 110 to
the frame 20 such that the tip shaper 60 moves in a linear direction
relative to the frame 20 and/or clamp 40 when the carriage 110 moves
along the linear slide 114. In one embodiment, a cam actuator 112 (FIG.
1) produces rotary movement which is converted into the linear movement
of the linear carriage 110 along the linear slide 114. It should be
appreciated that other types of mechanisms and actuators apparent to one
of skill in the art may be used to move the tip shaper 60 relative to the
frame 20 and/or clamp 40.

Counterweight

[0065]As indicated above, it may be desirable to configure the apparatus
so that a predetermined force may be maintained between the tip shaper 60
and an optical fiber 50 during the tip shaping process regardless of the
orientation of the apparatus. This may be particularly advantageous for a
handheld device.

[0066]As shown in FIGS. 2 and 8, aspects of the present invention
contemplate an apparatus for shaping an optical fiber 50 which include a
counterweight 200 supported by the frame 20. In one illustrative
embodiment, the counterweight 200 is arranged to maintain a predetermined
force between the tip shaper 60 and an end 52 of an optical fiber 50 when
the tip shaper 60 is shaping the fiber 50. This predetermined force may
be maintained independent of the orientation of the tip shaper and/or the
optical fiber 50.

[0067]The orientation of the apparatus may cause gravity to affect the
force between the tip shaper 60 and the optical fiber 50. For example,
when the apparatus 100 is in the vertical position shown in FIG. 1 to
contact a downwardly facing optical fiber end 52, gravity may decreases
the force exerted by the tip shaper due to the weight of the apparatus
100 components being drawn away from the optical fiber end 52. In this
orientation, the force between the tip shaper 60 and the end 52 of the
optical fiber 50 may be lower than a desired force for shaping the fiber
50. This may result in the end 52 of the fiber 50 not meeting the desired
end surface characteristics and/or it may increase the amount of time
required to shape the fiber 50.

[0068]In contrast, when the apparatus 100 is oriented in a position to
contact an upwardly facing optical fiber end 52, gravity may increase the
force exerted by the tip shaper due to the weight of the apparatus 100
components being pulled toward the optical fiber end 52. In this
orientation, the force between the tip shaper 60 and the end 52 of the
optical fiber 50 may be higher than a desired force for shaping the fiber
50. This may result in the end 52 of the fiber becoming damaged or even
broken.

[0069]In the illustrative embodiment, the counterweight 200 is provided to
reduce the variation in the force between the tip shaper 60 and the end
52 of the optical fiber 50 due to gravity. In one embodiment, the
counterweight 200 is moveable in a linear direction relative to the frame
20. As illustrated, a linear slide 202 couples the counterweight 200 to
the frame 20. In other embodiments, the counterweight may move in a
non-linear direction, as the invention is not so limited. In one
embodiment, when the orientation of the apparatus 100 changes, the
counterweight 200 may be configured to move along the linear slide 202.

[0070]In one embodiment, the counterweight 200 may be configured to move
in response to movement of the linear carriage 110, but in the opposite
direction, such that the counterweight 200 counteracts the weight of the
linear carriage 110. For example, in one embodiment, if the linear
carriage 110 moves 1 centimeter to the left, the counterweight may be
configured to move 1 centimeter to the right to counteract this movement
of the linear carriage 110. In this respect, the effect of gravity on the
weight of the apparatus components, such as the linear carriage 110 and
tip shaper 60, is reduced so that varied orientations of the apparatus
will not adversely affect the predetermined shaping force between the tip
shaper 60 and the end 52 of the fiber.

[0071]In one illustrative embodiment, a pulley system 210 is provided to
facilitate slidable movement of the counterweight 200 relative to the
frame 20. In the illustrative embodiment, the pulley system 210 couples
the counterweight 200 to the tip shaper 60 such that the counterweight
moves when the tip shaper and linear carriage move. In one illustrative
embodiment, the pulley system 210 includes a pair of pulleys 212 coupled
to the frame 20 at spaced apart locations. The pulley system 210 further
includes a cable 214 coupled to the counterweight 200 and extending
around each pulley 212. Movement of the linear carriage 110 and tip
shaper 60 may generate rotation of the pulleys 212 which slidably moves
the counterweight 200 relative to the frame 20 in the direction opposite
the movement of the linear carriage 110. A spring 216 may be provided on
the cable 214 to maintain the cable in tension regardless of the
orientation of the apparatus.

Fiber Support

[0072]As indicated above, it may be desirable to support the optical fiber
during the shaping process. Aspects of the present invention contemplate
a fiber support 140 arranged to support an end portion of the optical
fiber 50. The fiber support 140 may be moveable along the end portion of
the fiber 50 in response to the tip shaper 60 shaping the end of the
optical fiber 50.

[0073]In one illustrative embodiment shown in FIGS. 11-13, a fiber support
140 is shown in greater detail. In particular, FIGS. 11 and 12 illustrate
a fiber support assembly 160 in assembled and exploded views, whereas
FIG. 13 illustrates the fiber support assembly 160 coupled to the clamp
40.

[0074]In one illustrative embodiment, the fiber support assembly 160
includes a fiber support 140 which may be at least partially enclosed
within a fiber support housing 142.

[0075]The fiber support 140 is movable along an end portion 56 of the
optical fiber 50 in response to the tip shaper 60 shaping the end of the
optical fiber 50. As the tip shaper 60 contacts and abrades the fiber 50,
the fiber may be worn away by the abrasion process.

[0076]In one embodiment, the fiber support 140 moves away from the tip
shaper 60 once the tip shaper contacts the fiber support 140. In the
illustrative embodiment, the fiber support 140 is moveable in an axial
direction along the fiber axis 162, and contact by the tip shaper 60 on
the fiber support 140 moves the fiber support 140 toward and into the
fiber support housing 142.

[0077]The fiber support 140 is constructed to support an end portion 56 of
the optical fiber 50. In one illustrative embodiment, the fiber support
140 has an axial passage 150 adapted to receive the optical fiber 50
therethrough. As shown, the fiber support may be configured to be
substantially cylindrical shaped and the axial passage 150 may extend
through the center of the fiber support 140. In one embodiment, the fiber
support 140 may act as a floating ferrule that is slidable relative to
the end portion of the optical fiber. It should be appreciated that in
other embodiments, the fiber support 140 may be shaped differently as the
invention is not so limited.

[0078]In one illustrative embodiment, the fiber support 140 is biased in a
direction toward the tip shaper 60. As shown in FIGS. 12 and 13, a spring
144 may be provided to bias the fiber support 140 in the direction of
arrow D (FIG. 13). In a relaxed position, a portion of the fiber support
140 may extend out from the fiber support housing 142. When the tip
shaper 60 contacts and shapes the end of the optical fiber 50, the fiber
support 140 may move along the fiber to expose the end of the optical
fiber for shaping. When the tip shaper 60 moves away from the optical
fiber 50, the spring 144 biases the fiber support 140 to move in the
direction of arrow D to return to the relaxed position.

[0079]In one illustrative embodiment, the fiber support housing 142 may
include an end cap 146 and fasteners 148 to enclose the fiber support 140
within the fiber support housing 142. The end cap 146 may include an
opening 152 which communicates with the opening 352 in the apparatus
housing 350 as discussed in more detail below and as illustrated in FIG.
14. It should be recognized that in other embodiments, a moveable fiber
support 140 may be configured differently, and may for example be
incorporated into the clamp 40.

Abrasive Substrate

[0080]Aspects of the present invention are directed to the abrasive
substrate 70. The abrasive substrate 70 may be formed of various
materials and includes at least one abrasive surface which is configured
to shape an end 52 of the optical fiber 50. In one embodiment, the
abrasive surface is formed with an abrasive diamond film. In other
embodiments, it is contemplated that the abrasive substrate may be formed
with other materials such as, but not limited, to silicon carbide and/or
aluminum oxide.

[0081]As mentioned above, in one embodiment, the abrasive substrate 70 may
be made from a material that is similar to a sandpaper-like material, and
movement of the tip shaper 60, which includes the abrasive substrate 70,
shapes or abrades the end of the optical fiber 50.

[0082]The abrasive characteristics of the abrasive substrate 70 may also
vary based upon the particular application. A coarse abrasive substrate
70 may produce a rougher surface and may be used when a larger amount of
material is desired to be abraded from the optical fiber and a fine
abrasive substrate 70 may produce a smoother surface and may be used when
a smaller amount of material is desired to be abraded from the optical
fiber.

[0083]In one illustrative embodiment, a coarse abrasive substrate 70 may
include 6 micron diamond, which is approximately equivalent to 3000 grit.
In one illustrative embodiment, a fine abrasive substrate 70 may include
1 micron diamond, which is approximately equivalent to 14,000 grit. In
one illustrative embodiment, a fine abrasive substrate 70 may include
0.25 micron diamond, which is approximately equivalent to 100,000 grit,
and in yet another embodiment, a fine abrasive substrate 70 may include
0.1 micron diamond.

[0084]Aspects of the present invention are directed to an abrasive
substrate 70 having regions with different abrasive properties. In this
respect, a first region of the abrasive substrate 70 may contact and
abrade the optical fiber 50, and thereafter a second region of the
abrasive substrate 70 having abrasive properties which are different from
the first region may contact and abrade the optical fiber 50.

[0085]In one illustrative embodiment, the abrasive substrate 70 may
include a plurality of regions with different abrasive properties along
the length of the substrate 70. It is contemplated that the abrasive
substrate 70 may be configured to have coarse abrasive properties at one
end of the substrate 70 and fine abrasive properties at the other end of
the substrate 70. In this respect, it may be desirable to start off
shaping the optical fiber with a coarse substrate to remove a sufficient
amount of material, while ending the shaping process with a fine
substrate to achieve a smooth and/or flat end surface.

[0086]It is also contemplated that the abrasive properties of the
substrate may progressively change over each region. For example, in one
embodiment, each region of the abrasive substrate 70 is progressively
more coarse, and in another embodiment, each region of the abrasive
substrate 70 is progressively more fine. Furthermore, it is also
contemplated that along the length of the abrasive substrate 70 the
abrasive properties of each region may vary from coarse to fine to coarse
and so on.

[0087]An abrasive substrate 70 having a plurality of regions with
different abrasive properties may be formed with a plurality of different
abrasive materials. In one embodiment, the abrasive substrate 70 may
include a base substrate with a plurality of abrasive materials fixed to
a top surface of the base substrate. It is contemplated that the
plurality of abrasive materials may be fixed to the base substrate with
an adhesive at desired locations.

[0088]Turning to FIGS. 10A-10D, one illustrative embodiment of an abrasive
substrate 300 will now be described in greater detail. In this particular
embodiment, multiple layers of abrasive material form the abrasive
substrate 300. As illustrated in FIG. 10D, the abrasive substrate 300 has
at least a first region 340 and a second region 342 adjacent the first
region 340. The first region 340 has first abrasive properties and the
second region 342 has second abrasive properties that are different from
the first abrasive properties to provide different shaping
characteristics along the abrasive substrate. As illustrated, in one
embodiment, the abrasive substrate 300 may further include a third region
344 adjacent the second region 342, where the third region 344 has third
abrasive properties which are different from the first and second
abrasive properties to provide different shaping characteristics along
the abrasive substrate.

[0089]It should be appreciated that it is also contemplated for the
abrasive substrate 300 to include one or more additional regions, as the
present invention is not limited to a particular number of regions having
different abrasive properties. It should also be recognized that an
abrasive substrate having a plurality of regions with different abrasive
properties may be formed with one or more layers as the present invention
is not so limited.

[0090]In one illustrative embodiment, the abrasive substrate 300 includes
a first layer 310 and a second layer 320 disposed over the first layer
310. The second layer 320 may have a first opening 322 extending
therethrough to expose a portion of the first layer 310. In this
particular embodiment, the portion of the first layer 310 which is
exposed through the opening 322 forms the first region 340 and at least a
portion of the second layer 320 forms the second region 342 adjacent the
first region 340.

[0091]The abrasive substrate 300 may include one or more additional layers
to form additional abrasive regions, if desired. In the embodiment
illustrated in FIGS. 10A-10D, the abrasive substrate 300 includes a third
layer 330 which is disposed over the second layer 320. The third layer
330 may have a second opening 332 extending therethrough to expose a
portion of the second layer 320. In this particular embodiment, the
portion of the second layer 320 which is exposed through the second
opening 332 forms the second region 342 and at least a portion of the
third layer 330 forms the third region 344 adjacent the second region
342.

[0092]In one illustrative embodiment, as shown in FIGS. 10A-10D, the
plurality of regions 340, 342, 344 having different abrasive properties
may be repeated along the length of the abrasive substrate 300. When the
apparatus 100 is configured such that the abrasive substrate 300 is
advanced toward the optical fiber in the direction of arrow C, an end 52
of the optical fiber 50 may first contact and be shaped by the third
region 344 of the abrasive substrate 300. Thereafter, the substrate 300
may be advanced along the substrate support 72 such that the end of the
optical fiber 50 contacts and is shaped by the second region 342, which
may be followed by the substrate 300 being advanced such that the fiber
contacts and is shaped by the first region 340. After the optical fiber
contacts the first region 340, the substrate 300 may continue to be
advanced in the direction of arrow C and the optical fiber may next
contact and be shaped by another third region 344, followed by another
second region 342 and another first region 340. The apparatus may be
configured to employ one or more of such cycles to shape the tip of one
optical fiber and/or to shape the tips of a plurality of optical fibers.

[0093]In one illustrative embodiment, the third layer 330 includes a
coarse abrasive surface, the second layer 320 includes a medium abrasive
surface, and the first layer 310 includes a fine abrasive surface. Thus,
as the substrate 300 is advanced in the direction of arrow C, the optical
fiber is shaped by regions which go from coarse to fine. In one
illustrative embodiment, the third layer 330 may include 6 micron
diamond, the second layer 320 may include 1 micron diamond and the first
layer 310 includes 0.1 micron diamond. It should be appreciated that in
other embodiments, the regions and layers of the abrasive substrate 300
may be arranged differently and employ various levels of coarseness or
fineness, as the invention is not so limited.

[0094]The type of material used for the abrasive substrate 300 will also
vary on the type of material being shaped by the apparatus. As mentioned
above, the end of the optical fiber to be shaped by the apparatus may be
substantially bare (i.e., where various components, such as a ferrule,
and coatings have been removed or stripped from the fiber), or the fiber
may include one or more coatings and or components, such that shaping the
end of the optical fiber may also shape the coatings and/or components.
An optical fiber having various coatings and/or components may require a
different type of abrasive substrate material than a bare optical fiber.
In particular, an optical fiber that includes coatings and/or other
components, such as a ferrule fixed to the end of the fiber 50, may
require a coarse abrasive substrate to shape the end face.

[0095]It may be desirable to moisten the abrasive substrate 70 with a
fluid. Various types of fluids may be used to wet the abrasive substrate
70 as the present invention is not limited in this respect. In one
illustrative embodiment, an abrasive substrate 70 may require an
activation fluid which may transfer the abrasive substrate 70 into a
slurry. In one illustrative embodiment, a coarse abrasive substrate may
require a lubrication fluid. In one illustrative embodiment, a fluid may
be used to clean the optical fiber after the abrasive substrate 70 shapes
the fiber 50. In such embodiments, the tip shaper 60 may include a fluid
dispenser 94 (FIG. 1) configured to dispense a fluid to wet at least a
portion of the abrasive substrate 70 with the fluid.

[0096]In some situations, it may be desirable to remove the fluid from the
abrasive substrate 70 and/or the end face 52 of the optical fiber. For
example, a fluid may also act as a contaminant itself. Therefore,
according to one embodiment, the tip shaper 60 may include a fluid
collector 98 (FIG. 1) configured to collect a portion of the dispensed
fluid. In one illustrative embodiment, the fluid collector 98 may include
a sponge-like material that collects the fluid by absorbing fluid from
the substrate into the sponge-like material.

[0097]It should be recognized that the apparatus 100 may not include a
fluid dispenser 94 and/or a fluid collector 98, as the invention also
contemplates the use of abrasive substrates 70 which do not need to be
moistened.

Automation of Shaping Apparatus

[0098]Aspects of the present invention are directed to an automated
apparatus for shaping an end of an optical fiber. An apparatus with one
or more automated features may enhance the effectiveness of achieving an
end face with desirable surface characteristics during repair and/or
maintenance work.

[0099]In one illustrative embodiment shown in FIG. 14, the apparatus 100
may include a housing 350 configured to allow an operator to hold the
device. In one embodiment, the apparatus is a handheld device so that an
operator may more easily use the apparatus in a field environment to
repair an optical fiber and the housing 350 may be shaped to fit within
an operator's hand. The housing 350 may include an opening 352 which is
adapted to receive an optical fiber to initiate the tip shaping process
and the operator may align and insert the end 52 of the optical fiber 50
into the opening 352.

[0100]In one illustrative embodiment, when the apparatus 100 is aligned
with the end of the optical fiber, an operator may actuate a trigger 354
to actuate an automatic shaping process or cycle. Once the shaping
process is actuated, the operator holds the apparatus 100 until the
shaping process is completed. The apparatus 100 may include an indicator
360, such as an LED, which signals to the operator that the process is
complete, such that the operator will know when he/she can remove the
shaping apparatus 100 from the optical fiber.

[0101]An automated device may be advantageous by allowing less skilled
technicians to prepare fiber ends for subsequent processing. In this
regard, once the operator actuates the trigger 354, no further input may
be required to achieve an end face having desirable surface
characteristics.

[0102]It is contemplated that one or more processes may be automated,
including, but not limited to, movement of the tip shaper 60 in the first
direction toward and away from the clamp 40, movement of the tip shaper
in the second direction in a plane transverse to the first direction to
shape the optical fiber, advancement of the abrasive substrate along at
least a portion of the substrate support 72, and application of the fluid
to the abrasive substrate.

[0103]Various types of controls may be incorporated into the shaping
apparatus 100 to automate the processes of the apparatus. In one
illustrative embodiment shown in FIG. 15, a main processor 400 may
interact with and actuate one or more controllers.

[0104]A linear carriage controller 402 may provide an actuator control
signal to control the linear movement of the tip shaper 60.

[0105]An orbital carriage controller 404 may provide a rotation control
signal to the orbit motor 80 (see FIG. 3) to actuate rotation of the tip
shaper in response to an actuator control signal.

[0106]An abrasive substrate feed controller 406 may provide a drive
control signal to the drive mechanism to advance the abrasive substrate
along the substrate support 72. The abrasive substrate feed controller
406 may provide a drive control signal to the drive motor 130 (FIG. 6) to
unwind the abrasive substrate 70 from the first reel 90.

[0107]A fluid dispensing controller 408 may provide a fluid control signal
to the fluid dispenser 94 to control and maintain the volume and timing
of fluid dispensed onto the abrasive substrate 70.

[0108]An operator signaling controller 410 may be provided to inhibit the
actuation of the apparatus 100 until it is positioned in a desired
location. In one illustrative embodiment, the apparatus may be configured
so that it cannot be actuated until the apparatus is aligned with an
optical fiber. This may help to prevent inadvertent waste of the abrasive
substrate 70. In one embodiment, a sensor may be located on the apparatus
to determine whether an end of an optical fiber has been inserted into
the opening 352 in the housing 350 (see FIG. 14). If the sensor does not
detect an optical fiber, the operator will be unable to actuate the
automated shaping process by actuating the trigger 354. However, once the
sensor detects that an optical fiber has been inserted into the apparatus
100, the operator may initiate the automated process. In one embodiment,
an indicator may be provided to signal the operator that he/she may
actuate the process once an optical fiber has been inserted into the
opening 352 in the housing 350. It should be appreciated that various
types of sensors, such as proximity sensors and optical sensors, may be
used as the present invention is not so limited.

[0109]Software or firmware may control the desired sequence of the
automated operation of the shaping process. Although the specific
sequence may be programmed for certain applications, the following
sequence of automated operations is contemplated by the present
invention. First, a sensor may detect when an optical fiber is positioned
within opening 352 in the apparatus housing 350. A signal may then be
sent to the operator via the indicator 360, to signal the operator that
the shaping process may be initiated. Thereafter, the operator may
actuate the automated cycle by actuating the trigger 354.

[0110]Once initiated, the main processor 400 may signal the tip shaper 60
to extend linearly to contact the end face of the optical fiber. The main
processor 400 may also initiate the orbital rotation of the tip shaper 60
which may occur to shape the end of the optical fiber. If desired, the
processor may also signal the dispensing of fluid onto the substrate 70
at predetermined intervals. The main processor 400 may also actuate
advancement of the abrasive substrate 70 along the substrate support 72.
Once the fiber is shaped with the abrasive substrate 70 to achieve the
desired surface characteristics, the main processor 400 may signal the
tip shaper 60 to return to its original orbital orientation, signal the
fluid dispenser 94 to cease dispensing fluid, and/or signal the tip
shaper 60 to retract away from the optical fiber 50. The main processor
400 may further provide a signal to cease the advancing of the abrasive
substrate 70 and thereafter a signal may be sent to the operator via the
indicator 360 to specify that the automated shaping process is completed
so that the operator may remove the apparatus from the optical fiber.

[0111]It is contemplated that the apparatus 100 may be cordless and
battery powered, and both the batteries and the main processor 400 may be
located within the housing 350. However, it should be appreciated that it
is also contemplated that components may reside outside of the housing 30
and/or that the apparatus may be powered by standard AC current.

Replaceable/Detachable Components

[0112]For some applications, it may be desirable for one or more
components of the shaping apparatus 100 to be detachable and replaceable.
For example, it may be desirable to replace the abrasive substrate 70
and/or the fluid dispenser 94 after they have been exhausted without
having to replace the entire apparatus. This may be desirable to maximize
the life of reusable components. It may also be desirable to replace the
substrate support 72 to vary the desired optical fiber end face surface
characteristics.

[0113]In one illustrative embodiment shown in FIG. 9, the abrasive
substrate 70 may be detachable and replaceable. For example, once the
supply of the abrasive substrate 70 provided on the first reel 90 is
exhausted, the used abrasive substrate 70 may be discarded and replaced
with a fresh supply of abrasive substrate 70.

[0114]In the illustrative embodiment of FIG. 9, the abrasive substrate 70
may be contained within a cartridge 96. In this particular embodiment,
the cartridge 96 supports the abrasive substrate 70, the first reel 90
and the second reel 92. In one illustrative embodiment, the cartridge 96
may be detachably coupled to the frame 20, and may for example be
detachably coupled to the orbital carriage 80.

[0115]To insert a new abrasive substrate 70 into the apparatus, the
operator may open a portion of the apparatus 100 to remove the spent
abrasive substrate cartridge 96 and replace it with a new abrasive
substrate cartridge. For example, in the embodiment illustrated in FIG.
14, the housing 350 includes an access door 356 with a handle 358 which
enables an operator to access the cartridge 96. The replacement process
may be similar to inserting a cassette into a cassette player. It is also
contemplated that the cartridge 96 may include features which engage with
features in the apparatus for a snap-fit. For example, as shown in the
embodiment illustrated in FIGS. 4 and 7, the orbital carriage 80 may
include one or more engagement clips 146 adapted to secure the cartridge
in a snap-fit relationship.

[0116]In one embodiment, the support substrate 72 may be detachable and
replaceable. The type of support substrate 72 may be chosen based upon
the desired end face surface characteristics. A support surface 72 having
a substantially rigid and flat support surface may be used to create a
flat optical fiber end face. A substrate support 72 having a non-planar,
non-rigid, and/or curved support surface may be used to create a
non-planar or curved optical fiber end face. In one embodiment, the
support substrate 72 may be contained with the cartridge 96 and may be
replaceable when the cartridge 96 is removed from the housing 350.

[0117]In one embodiment, one or more portions of the fluid dispenser 94
may be detachable so that when the fluid source is depleted, a new supply
of fluid may be added to the apparatus. It is contemplated that the fluid
may be added to a chamber of the fluid dispenser (not shown). However, it
is also contemplated that the apparatus may include a detachable fluid
chamber or fluid cartridge.

[0118]It should be appreciated that various embodiments of the present
invention may be formed with one or more of the above-described features.
The above aspects and features of the invention may be employed in any
suitable combination as the present invention is not limited in this
respect. It should also be appreciated that the drawings illustrate
various components and features which may be incorporated into various
embodiments of the present invention. For simplification, some of the
drawings may illustrate more than one optional feature or component.
However, the present invention is not limited to the specific embodiments
disclosed in the drawings. It should be recognized that the present
invention encompasses embodiments which may include only a portion of the
components illustrated in any one drawing figure, and/or may also
encompass embodiments combining components illustrated in multiple
different drawing figures.

[0119]It should be understood that the foregoing description of various
embodiments of the invention are intended merely to be illustrative
thereof and that other embodiments, modifications, and equivalents of the
invention are within the scope of the invention recited in the claims
appended hereto.